PROMATECT-L500

Self-supporting Ducts

Self-supporting Ducts
Systems Index

Type of
self-supporting ducts

PE

43

System
code

FRL

Board
thickness

Duct type

Mineral wool

Maximum
dimension

PE 43.30

30/30/30

25mm
40mm

A
B

Not required

3000mm x
1250mm

Not required

3000mm x
1250mm

PE 43.60

PE 43.90

PE 43.12

25mm

35mm

40mm

A
B

25mm

40mm

A
B

25mm

120/120/120

40mm

52mm

240/240/30

25mm
40mm

Not required

52mm

A
B

*50mm x
100kg/m3

60/60/60

90/90/90

PE 43.24
240/240/240

Not required

3000mm x
1250mm

Not required

3000mm x
1250mm

Tests and assessments

Page no.
standards/labs

BS476: Part 24 and

AS1530: Part 4
Report no.
BRE CC83903
BRE CC84890/89225J
BRE CC86825
WFRC C80557

3000mm x
1250mm

*For Duct type B only.

NOTE: For ducts exposed to external fire (Duct type A) the insulation can be measured inside the duct, inside the fire compartment or outside
the duct on an adjacent compartment. All the above provide similar levels of insulation to that listed, when the insulation is measured outside
the duct. For details of insulated ducts exposed to external fire where insulation is required inside the duct, or inside the fire compartment,
please consult Promat Technical Department.

Ductwork
General Information

The relative complexity of any ductwork system which is passing

through different fire compartments and the relevance of the
systems function in ambient as well as fire conditions can make the
selection of a suitable ductwork system difficult.
This section of the handbook aims to give some guidance on the fire
performance requirements of ductwork and offers a wide range of
solutions for the protection of steel ductwork and for self-supporting
systems using PROMATECT-H, and PROMATECT-L500.
For particularly onerous conditions, e.g. where high impact strength
is required or for use in aggressive environments, Promat have
developed a range of systems using the PROMATECT-S high
impact board.

Fire Testing Methods

To determine the fire resistance of ducts (without the aid of fire
dampers) passing through or between compartments, the system
should normally be tested or assessed in accordance with BS476:
Part 24 or AS1530: Part 4. These standards have been written
specifically for ventilation ducts, but guidance is also given in these
standards on the performance requirements for smoke outlet
ducts and kitchen extract ducts.
Although the following information refers to BS476: Parts 20 to 24,
these details apply equally to AS1530: Part 4 in terms of the
performance requirements. It should be noted, however, that there
are substantial differences between the two standards in terms of
testing methodology which greatly affect the results. It is not
possible to simply transfer results from AS1530: Part 4 test to
BS476: Part 24 due to this huge difference in testing methods.
A part of a standard fire test, duct systems are exposed to external
fire (also known as Duct type A) and one sample to both external
AND internal fire (also known as Duct type B). Fans create a
standard pressure difference and air flow and the ducts fire
performance is assessed in both fan-on and fan-off situations.
When testing horizontal ducts, a run of at least 3000mm is located
within the fire compartment (the EN and revised ISO standards
required a 4000mm length exposed) and a further 2500mm outside
the fire compartment.
BS476: Part 24 expresses the fire resistance of ducts without the
aid of dampers, in terms of stability, integrity and insulation.
Stability failure occurs when the suspension or fixing devices can
no longer retain a duct in its intended position or when sections
of the duct collapse. This requirement does not apply to the
length of the duct exposed to internal fire (Duct type B) within the
fire compartment.
It should be noted that if a duct suffers extensive deformation, such
that it can no longer fulfil its intended purpose, this would be
classed as stability failure. For Duct type A, loss of pressure within
the duct during testing is also construed as stability failure.

Integrity failure occurs when cracks, holes or openings occur in the

duct or at any penetrations within walls or floors, through which
flames or hot gases can pass. The effects on integrity of the
movement and distortion of both restrained and unrestrained ducts
are also included in the standard.
Insulation failure occurs when the temperature rise on the outer
surface of the duct outside the fire compartment exceeds 140C
(mean) or 180C (maximum). The guidance in the standard also
states that ducts lined with combustible materials or coated
internally with fats or greases, e.g. kitchen extract, should also have
this criterion for the inner surface of the duct within the fire
compartment when the duct is exposed to external fire (Duct A).
For smoke extraction, the guidance in the standard states that the
cross sectional area of a duct required to extract smoke in the event
of a fire should not be reduced by more than 25% for the duration
of the fire exposure.
See Penetration Through Walls & Floors on opposite page.

General Design Considerations

The following points are some of the factors which should be
considered when determining the correct specification to ensure a
ductwork system will provide the required fire performance.
Further advice can of course be obtained from the Promat
Technical Department.

1. Required Fire Exposure

Ductwork systems which are located in more than one
compartment should always be tested or assessed for their
performance when exposed to the heating conditions described
within BS476: Part 20. Reduced heating curves are generally only
acceptable for certain of the systems components, e.g. the fan.
The performance of a ductwork system will vary depending on
whether or not a fire could have direct access to inside the duct
through an unprotected opening. If in doubt, one should assume
direct access, i.e. the Duct B scenario described previously under
Fire Testing Methods.

2. Required Fire Performance

It is a general requirement that the ducts must satisfy all the relevant
performance criteria of stability, integrity and insulation (and cross
sectional area if a smoke extraction duct). However, the approval
authority may accept relaxations on occasion. For example, if no
combustible materials or personnel could be in contact with the
duct, the authority may accept a reduced insulation performance.

Ductwork
General Information
General Design Considerations
3. Supporting Structure
Care should be taken that any structural element from which the
duct system is supported, e.g. a beam, floor or wall, must have as
a minimum the same fire resistance as the duct system itself and
must be able to support the load of the duct under fire conditions.

4. Hanger Support
The supporting hangers, supports and their fixings should be
capable of bearing the load of the complete ductwork system
including any applied insulation material or other services
suspended from it. Chemical anchors are generally not considered
suitable. It is normally not advisable to use unprotected supports if
the stress exceeds the values given on page 5 and/or if hanger
lengths exceed 2000mm. The hanger centres should not exceed
the limits given in page 5.

5. Steel Ductwork
The steel duct must be constructed in accordance with the
requirements of DW/144 Specification for sheet metal ductwork
low, medium and high pressure/velocity air systems (published by the
Heating and Ventilating Contractors Association UK.), or equivalent
specification, e.g. SMACNA. The steel ducts must be constructed
with rolled steel angle-flanged cross joints. It is recommend that
longitudinal seams be formed using the Pittsburgh lock.

6. Penetrations Through Walls & Floors

Care should be taken to ensure that movement of the duct in
ambient or in fire conditions does not adversely affect the
performance of the wall, partition or floor, or any penetration seal.
It should be understood that where a duct passes through
any compartment wall or floor or other type of separating
element, the aperture between the element and the duct must be
sealed in accordance with the system approved for use with the
duct. In general this requires the use of a penetration seal
constructed from materials and in such a manner to match the
system used in the duct test programme. Penetrations seals are
part of the tested duct system and the use of untested third party
products are not permitted.

10. Other Requirements

Acoustic performance, thermal insulation, water tolerance, strength
and appearance can also be important considerations (See
BS8313: 1989 Code of practice for accommodation of building
services in ducts).

Selection of Fire Protection System

Traditionally all ductwork was fabricated from steel which normally
had to be encased in a fire protection system when passing through
a compartment wall or floor without the aid of a fire damper.
In recent years, self-supporting systems without a steel liner have
been introduced to extract smoke in the event of a fire through
natural ventilation. Now some self-supporting systems, e.g.
PROMATECT-H, PROMATECT-L500 and PROMATECT-S are
available which can match the leakage and air flow performance
of steel ducts in accordance with the DW144 standard up to
Class C.
To satisfy the wide range of requirements in the current market,
Promat can offer no less than three products to protect steel
ductwork and to fabricate self-supporting systems.
For any size of duct, the tensile stress in the steel hangers must not
exceed 10N/mm2 for fire resistance up to 120 minutes, or 6N/mm2
for fire resistance up to 240 minutes. These figures are based on
work carried out by Warrington Fire Research Centre (now
Bodycote) in the UK and European research projects into the stress
and strains of steel members under simulated fire conditions.
The stress reduction ratio factors mentioned below are based on
BS5950: Part 1: 1990. Similar figures can be applied from AS4600.
The method to calculate whether the diameter of the threaded rod
is within the permitted stress level is given below.
Fire resistance Approximate
Maximum
Maximum
period
temperature permitted stress permitted centres
30 minutes

840C

18/mm2

2500mm

60 minutes

950C

10/mm

2500mm

90 minutes

1000C

10/mm

2500mm

7. Movement Joints

120 minutes

1050C

10/mm

2500mm

Movement joint details may be required for long lengths of duct,

particularly where the duct spans across a movement joint in the
floor or wall, or passes through floors and roof that may deflect at
different rates. Please consult Promat Technical office for details of
such joints.

180 minutes

1110C

6/mm2

2000mm

240 minutes

1150C

6/mm2

1500mm

8. Air Flow & Leakage

The design of some fire resisting duct systems may need
modification to meet DW/144 performance standards. All Promat
self supporting duct systems will meet the requirements of DW/144
to the highest levels, provided the correct board thickness is
employed and all joints are correctly sealed in accordance with the
system recommendations.

9. Ductwork Functions
Most ductwork systems can fall into one or more of the
following categories:

It should be noted that the stress levels referred to above apply to

the threaded rod hanger supports themselves. The horizontal
members have a differing level of applicable stress (see page 5).
The maximum centres refers to the greatest allowable distance
between hanger support systems. However it should be noted that
in certain locations, bends for instance, additional supports at
lesser centres should be considered.
Where the hanger support system may exceed the limits given in
the table above the remedial options are as follows:
1) Increase the dimensions of the hanger support system, e.g. rod
diameters etc,
2) Reduce the centres of the hanger support system,
3) Protect the hanger rods.

Ventilation and air conditioning;

Natural smoke extract;
Fan assisted smoke extract;
Pressurisation of escape routes and fire fighting lobbies.
In the event of a fire, the function of a system can often change. For
example, an air conditioning system could switch to become a fan
assisted smoke extract duct. It is therefore essential that the
performance requirements in both normal conditions and fire
conditions are considered.
4

Hangers supporting steel ducts protected with Promat materials

can be left unprotected providing the maximum stress on each
hanger does not exceed the values given in the above table and
importantly that their length does not exceed 2000mm. Where
hanger rods exceed this dimension, there is a high risk of stability
failure of the duct due to excessive expansion of the support
system. If hanger rods exceed 2000mm, they should be
protected at all times for all systems, regardless of system type
or manufacturer.

Ductwork
General Information
Stress Calculation For Hangers
To calculate the stress in N/mm2 on each hanger, the total weight of
the ductwork and fire protection materials being taken by each
hanger should be calculated in kilograms, converted to Newtons (N)
by multiplying by 9.81 and then divided by the cross-sectional area
of the hanger in mm2. The cross-sectional area of a circular hanger
is x r2 where r is the radius of the support rod. It should be noted
that the root diameter of the threaded rod should be applied in this
calculation, not the outer diameter of the thread. Please refer to the
table below for details.
The method to calculate whether the diameter of the threaded rod
is within the permitted stress level is given below.

If these stress levels are exceeded then the size of the hanger
members must be increased, or the centres of the hangers reduced
or the hangers protected. The penetration of the hanger fixings
into any concrete soffit should be a minimum of 40mm for up to
120 minutes ratings or 60mm for more than 120 and up to 240
minutes ratings.
To calculate the stress of the horizontal supporting angle of channel,
the following would apply.
Board thickness (mm)

12

Duct height (m)

1.0

Duct width (m)

1.0

Nominal outer diameter

Root diameter

Cross sectional area

6mm

5.06mm

20.10mm2

Centres of hangers (m)

1.22

8mm

6.83mm

36.63mm2

Area of boards

(Width x 2) + (Height x 2) x
Centres of hangers

10mm

8.60mm

58.08mm2

Weight of boards

12mm

10.36mm

84.29mm2

Area x Thickness x
Density (975kg/m3)

14mm

12.25mm

117.85mm2

Weight of angles

16mm

14.14mm

157.03mm

(Centres of hangers x 4) +
(Width x 4) + (Height x 4) x
0.63kg/m

18mm

15.90mm

198.55mm2

Section weight (kg)

68.62 (inclusive of angles)

20mm

17.67mm

245.20mm2

Total force (N)

673 (Weight (kg) x 9.81 = N)

The density of steel is approximately 7850kg/m , therefore the

weight of steel (kg) = 7850 x surface area (m) x steel thickness (m).

Maximum bending
Moment, M

W x L2 = 101.79
8

The following example of calculating the stress of the support

system is based on the use of PROMATECT-H boards, however,
this method would apply to all fire resisting systems.

Stress, S

M < 19.5
Z
where Z is the
section modulus in cm3

Section modulus, Z

> M
19.5

> 4.7cm3

Board thickness (mm)

12

Duct height (m)

1.0

Duct width (m)

1.0

Centres of hangers (m)

1.22

Area of boards

(Width x 2) + (Height x 2) x
Centres of hangers

Weight of boards

Area x Thickness x
Density (975kg/m3)

Weight of angles

(Centres of hangers x 4) +
(Width x 4) + (Height x 4) x
0.63kg/m

Section weight (kg)

68.62 (inclusive of angles)

Weight on one hanger

34.31

Total force (N)

336.58 (Weight (kg) x 9.81 = N)

Diameter of steel rod (mm) =

Cross-section area (mm2)

38.63

Stress (N/mm2)

F
A

Using C-channels of uniform thickness in web and flanges, the

dimensions of channel:
Breath of channel (cm)

Depth of channel (cm)

Thickness of channel (cm) =

0.4

Section modulus

BxD2 - bxd2
6
6
4.9cm3

=
=

where F = force in Newton

where A = area of rod
cross section
8.71N/mm2

Since the stress is less than 10N/mm2 as set in the table above, an
8mm diameter rod is the minimum permissible for the duct of cross
section 1000mm x 1000mm x 1220mm length constructed with a
single layer of 12mm PROMATECT-H. If cladding a steel duct, the
weight of this has to be included within the total weight supported
upon the hangers.

Self-supporting Ducts
Duct Pressure & Type of Stiffeners

Duct type

System
code

Maximum
duct pressure
during fire

FRL

Board
thickness

30/30/30

PE

43.30/43.60/
43.90/
43.12/43.24

Type of stiffeners (see page 234)

Type 1

Type 2

25mm

60/60/60

25mm

90/90/90

25mm

120/120/120

25mm

30/30/30

40mm

60/60/60

40mm

500Pa

Type A:
Ducts exposed
to external fire

PE 43.30/
PE 43.60/
PE 43.90/
PE 43.12/
PE 43.24/

750Pa

1000Pa
- 2000Pa

500Pa

90/90/90

40mm

120/120/120

40mm*

240/240/240

52mm*

2 rows

2 rows

30/30/30

40mm

1 row

60/60/60

40mm

1 row

90/90/90

40mm

1 row

120/120/120

40mm*

1 row

240/240/240

52mm*

2 rows

30/30/30

25mm

60/60/60

35mm

240/240/30

25mm

30/30/30

40mm

60/60/60

40mm

90/90/90

40mm

240/240/30

40mm

1 row

1 row

30/30/30

40mm

1 row

60/60/60

40mm

1 row

90/90/90

40mm

1 row

120/120/120

52mm*

1 row

240/240/240

52mm with
mineral wool
50mm x 100kg/m3

2 rows

750Pa
Type B:
Ducts exposed
to internal fire

PE 43.30/
PE 43.60/
PE 43.90/
PE 43.12/
PE 43.24/

1000Pa
- 2000Pa

Maximum
dimension

1200mm x 1200mm
or
3000mm x 1250mm

1200mm x 1200mm,
2000mm x 1250mm
or
3000mm x 1250mm

1440mm x 700mm,
1800mm x 600mm
or
800mm x 600mm

1200mm x 1200mm
or
3000mm x 1250mm

1200mm x 1200mm,
2000mm x 1250mm
or
3000mm x 1250mm

1440mm x 700mm,
1800mm x 600mm
or
800mm x 600mm

*For performance to AS1530: Part 4, duct constructed 52mm PROMATECT-L500 boards, external fire (temperature measured inside duct) FRL 120/120/60. For internal fire
FRL 120/120/90. To obtain FRL 120/120/120, use 400mm wide collar, see details of 3 on page 7.

Self-supporting Ducts
(Integrity & Insulation)

PE

43.30/43.60/
43.90/
43.12/43.24

Ma

xim

T E C H N I C A L

um

10

me

tre

D A T A

1 layer of PROMATECT-L500 board in accordance with FRL and

operating pressure requirements, see table on opposite page.

1 layer of PROMATECT-H cover strips,

100mm wide x 9mm thick according to the desired FRL.

1 layer of PROMATECT-L500 collars, minimum 80mm wide or

400mm wide (for Australia only, when using 52mm thick of 1 for
FRL of 120/120/120 for internal fire exposure) x board thickness
according to the desired FRL, fitted around the duct on both sides
on the wall forming an L-shape.

Optional steel angles 40mm x 20mm x 0.6mm thick

Duct hanger system, stress calculation according to page 5.

Steel angles minimum 30mm x 30mm x 3mm thick according to

duct weight and size and maximum permitted stress levels

Fixings in accordance with the table below, care should be taken

not to overtighten screws. When edge fixing it is advisable to drill
pilot holes.
Board
thickness

Deep threaded drywall type screws,

preferably with ribbed heads
at 200mm centres

Staples at
100mm centres

25mm

No.6 x 50mm

63/11/1.5mm

35mm

No.8 x 63mm

70/12/2mm

40mm

No.8 x 75mm

80/12/2mm

50-52mm

No.10 x 100mm

90/12.2/2.3mm

PROMASEAL AN Acrylic Sealant at all board joints

M6 anchor bolts at nominal 600mm centres

10

1 layer of mineral wool tightly packed into aperture between

substrate and the surface of the self-supporting duct, including an
approximately 30mm between the substrate and the collars.

Details of wall penetration

PROMATECT-L500 self-supporting ducts must be supported at maximum 1250mm centres, located to coincide with joints, or to one side of
joint. No protection is required to the support angle or channel unless each hanger is more than 50mm from the duct sides. In this case, the
support section should be clad as shown above. Vertical duct runs normally require to be tied back to an adjoining masonry wall using threaded
rods and angle or channel support section at maximum 3000mm centres.
For selection of board thickness, it will not only depend on the required fire performance but also on the internal cross section of the duct and
the operating pressure(s). With large ducts and medium to high operating pressures, internal stiffeners may be required. See page 8. Please
consult Promat if the operating pressure exceeds 1000Pa.
The above construction of self-supporting fire resistant encasements around is up to 10 metres wide in accordance with the criteria of BS476:
Part 24 and AS1530: Part 4, exposed to external and internal fire. Please consult Promat Technical Department for duct width over 3m.
For impact resistant systems in accordance with the criteria BS5669: Part 1 exposed to external and internal fire, 52mm thick PROMATECTL500 boards are required. Insulation will be as Duct type B (exposed to internal fire).
7

Self-supporting Ducts
(Integrity & Insulation) Fixing Details
Construction type 1 of internal stiffeners

imum
Max mm
600

mum
Mini mm
0
5
2

Construction type 2 of internal stiffeners

PE

T E C H N I C A L

43.30/43.60/
43.90/
43.12/43.24

D A T A

1 layer of PROMATECT-L500 board, see page 6 for details.

PROMATECT-L500 stiffeners
minimum 40mm thick x 250mm wide

1 layer of PROMATECT-L500 collars, minimum 80mm wide x

board thickness according to the desired FRL, fitted around
the duct on both sides on the floor slab forming an L-shape.

PROMASEAL AN Acrylic Sealant at all board joints

PROMASTOP Cement or PROMASEAL Mortar

Fixings of deep threaded drywall type screws or steel wire

staples in accordance with the table on page 7, care should
be taken not to overtighten screws. When edge fixing it is
advisable to drill pilot holes.

M6 anchor bolts at nominal 600mm centres

Maximum duct pressures

The basic construction design is adequate for PROMATECT-L500
ducts with a maximum internal cross-section of 1200mm x
1200mm for operating pressures up to 500Pa.
This limit can be increased to 750Pa if the board thickness is
40mm or greater. For larger ducts and greater operating pressures,
internal stiffeners of either type shown here are required.
Internal stiffeners
Stiffeners are constructed with strips of minimum 250mm wide
PROMATECT-L500 board and fixed at maximum 600mm centres
(Type 1).

mum
Mini mm
250

Where a duct is subdivided by a solid PROMATECT-L500 board,

stiffeners are required with holes cut within the wall of a size and
quantity to ensure equal crossflow of air between the two halves
(Type 2).
Types of these stiffeners are specified on page 7 for the applicable
FRLs and maximum duct pressures.
Masonry or concrete wall penetration

Concrete floor slab penetration

The duct should pass through the wall opening without interruption.
The penetration is sealed with mineral wool and PROMATECTL500 collars are fitted around the duct on both sides on the wall
forming an L-shape. See opposite page.
For lightweight framed partition penetration, please consult Promat
Technical Department.
Concrete floor slab penetration
Same for the wall penetration, the duct should pass through
the floor opening without interruption. The gap is sealed
with PROMASTOP Cement or PROMASEAL Mortar and
PROMATECT-L500 collars are fitted around the duct on both
sides on the floor, forming an L-shape, to transfer the load of the
duct to the floor.

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1. This document is formulated on the basis of information and experience available at the time of preparation. Promat is constantly
reviewing and updating all of its test data and reserves the right to change specifications without notice.
2. Promat is not responsible if recipients of fire test reports, assessments or literature incorrectly interpret their contents and use
products based on those interpretations.